Base component with a bulk molded compound and no base coat

Patent metadata

Field	Value
Publication number	US-2025197626-A1
Application number	US-202318541599-A
Country	US
Kind code	A1
Filing date	Dec 15, 2023
Priority date	Dec 15, 2023
Publication date	Jun 19, 2025
Grant date	—

Abstract

A body composition with: a bulk molded compound (BMC) with: one or more thermoset resins; one or more fillers; one or more reinforcements; one or more binders; two or more inhibitors; and recycled body composition materials (recycled BMC); wherein the recycled BMC is a cured material that is processed and added into the body composition.

First claim

We claim:

1 . A body composition comprising:
a bulk molded compound (BMC) comprising:
one or more thermoset resins;
one or more fillers;
one or more reinforcements;
one or more binders;
two or more inhibitors; and
recycled body composition materials (recycled BMC);
wherein the recycled BMC is a cured material that is processed and added into the body composition.

2 . The body composition of claim 1 , wherein recycled BMC is added in an amount of about five percent or more of a total weight of the body composition.

3 . The body composition of claim 2 , wherein the recycled BMC comprises a cured bulk molded compound resin material.

4 . The body composition of claim 2 , wherein the recycled BMC comprises a cured poly(methyl methacrylate) PMMA resin material.

5 . The body composition of claim 1 , wherein the recycled BMC comprises a mixture of a cured bulk molded compound resin material and a cured poly(methyl methacrylate) PMMA resin material.

6 . The body composition of claim 5 , wherein the recycled BMC is present in an amount of about ten percent or more of a total weight of the body composition.

7 . The body composition of claim 1 , wherein the reinforcement is chopped glass fibers and crushed glass and the reinforcement is present in an amount from about 5 percent or more to about 30 percent or less by weight of the total weight of the BMC.

8 . The body composition of claim 1 , wherein the two or more inhibitors are three different inhibitors.

9 . A lighting component comprising:
a body component comprising:
a body composition comprising:
a bulk molded compound resin (BMC);
one or more fillers;
two or more inhibitors; and
recycled body composition materials (recycled BMC);

wherein the recycled BMC is cured material of the body composition that is processed and added into the body composition.

10 . The lighting component of claim 9 , further comprising:
a coating located directly on the body component so that the coating connects directly to the body component.

11 . The lighting component of claim 9 , wherein the recycled BMC is present in an amount of about 5 percent or more and about 20 percent less of the total weight of the body composition.

12 . The lighting component of claim 1 , wherein the recycled BMC comprises a mixture of a cured bulk molded compound resin material and a cured poly(methyl methacrylate) (PMMA) resin material.

13 . The lighting component of claim 9 , wherein the recycled BMC has a hardness that is three Mohs or more.

14 . The lighting component of claim 10 , wherein the body composition is free of a base coat between the body composition and the coating.

15 . The lighting component of claim 14 , wherein the one or more fillers comprise clay, talc, alumina trihydrate, glass, or a combination thereof.

16 . The lighting component of claim 15 , wherein the one or more fillers are present in an amount from about 40 percent to about 80 percent by weight of the BMC.

17 . The lighting component of claim 16 , wherein recycled BMC is added as one of the one or more fillers.

18 . The lighting component of claim 9 , wherein the body composition comprises virgin poly(methyl methacrylate) PMMA resin in addition to the BMC resin.

19 . A process comprising:
forming a bulk molded compound (BMC) comprising:
one or more thermoset resins;
one or more fillers;
one or more reinforcements; and
one or more binders;

combining the bulk molded compound with recycled body composition materials (recycled BMC), that has been cured, to form a body composition; molding the body composition into a body component of a lighting component; and curing the BMC.

20 . The process of claim 19 , further comprising:
processing the recycled BMC by reducing a size of the recycled BMC, wherein the recycled BMC is present in an amount of about 5 percent or more and about 20 percent less of the total weight of the body composition.

Assignees

• Valeo Vision

Inventors

• Fraizer Robert
• Adaska Scott

Classifications

• C08L2207/20

  Recycled plastic · CPC title

• C08L2205/025

  containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure · CPC title

• C08K7/14

  Glass · CPC title

• C08J2433/12

  Homopolymers or copolymers of methyl methacrylate · CPC title

• C08J2333/12

  Homopolymers or copolymers of methyl methacrylate · CPC title